Wall Box Dimmer

ABSTRACT

A dual function air-gap switch actuator ( 26 ) is incorporated into the generally planar face of a wall box dimmer. The switch actuator is finger operated and provides both a main power disconnect via air-gap contacts ( 211 ) and the means ( 212 ) to activate a secondary function. The dual function air-gap switch actuator is optionally fitted with an indicator lamp ( 265 ).

BACKGROUND OF THE INVENTION

1. Technical Field

This invention relates to wall box mounted lighting dimmers and moreparticularly relates to a dimmer having a bezel kit with a dual functionair-gap switch and configurable buttons.

2. Background Art

Wall box dimmers are well known and frequently have a triac, a siliconcontrolled rectifier (SCR), a field effect transistor (FET), or anyother controllably conductive semiconductor structure that is operableto deliver variable power to a lighting load. The controllablyconductive device is frequently provided with an on/off control actuatorand a dimmer level control actuator mounted in and operable from thefront surface of the dimmer. It is required, in order to be “UL listed”,to also provide a dual function air-gap switch actuator, which can belocated in and operated from the same front surface of the device toprovide a definite disconnect of the alternating-current (AC) power fromthe lighting load, independent of the off-time of the controllablyconductive power device.

It is very desirable to organize the control actuators on the frontsurface of the dimmer to present an attractive smooth and unclutteredappearance while also being easy to configure with various combinationsof buttons to allow ready customization.

The inventors have discovered that it would also be very desirable toutilize a required air-gap switch to provide additional functionalitywhen it is not being used to interrupt an external AC load and to evencombine a “night-light” feature into such a switch.

SUMMARY OF THE INVENTION

It is to be understood that both the general and detailed descriptionsthat follow are exemplary and explanatory only and are not restrictiveof the invention.

A first object of the present invention is to provide a wall box dimmerhaving a generally planar face and adapted to mount behind a faceplate.The dimmer includes an enclosure, a pair of cooperating air-gap contactsconfigured as a micro-switch mounted within the enclosure, and aremovable color matched bezel kit including components protrudingthrough an opening in the faceplate. The bezel kit further includes abezel, a dual function air-gap switch actuator configured as a lever,and a vertical column of light emitting diodes. The dual functionair-gap switch is mechanically co-operable with the pair of air-gapcontacts and operates to open and close these contacts. The bezel kit isconfigured to allow various sized buttons operable by the user toinitiate a primary function to be snapped into the bezel prior toattachment with the dimmer enclosure. The air-gap contacts are adaptedto open when the bezel kit is separated from the dimmer enclosure. Thedual function air-gap switch actuator is further adapted to be operableby the user to initiate an internal software reset.

A second object of the present invention is to provide a wall box dimmerhaving a generally planar face and adapted to mount behind a faceplate.The dimmer includes an enclosure, a pair of cooperating air-gap contactsconfigured as a micro-switch mounted within the enclosure, and aremovable color matched bezel kit including components protrudingthrough an opening in the faceplate. The bezel kit further includes abezel, a dual function air-gap switch actuator configured as a lever,and a vertical column of light emitting diodes. The dual functionair-gap switch is mechanically co-operable with the pair of air-gapcontacts and operates to open and close these contacts. The bezel kit isconfigured to allow various sized buttons operable by the user toinitiate a primary function to be snapped into the bezel prior toattachment with the dimmer enclosure. The air-gap contacts are adaptedto open when the bezel kit is separated from the dimmer enclosure. Thedual function air-gap switch actuator is further adapted to be operableby the user to adjust stored lighting preset levels.

A third object of the present invention is to provide a wall box dimmerhaving a generally planar face and adapted to mount behind a faceplate.The dimmer includes an enclosure, a pair of cooperating air-gap contactsconfigured as a micro-switch mounted within the enclosure, and aremovable color matched bezel kit including components protrudingthrough an opening in the faceplate. The bezel kit further includes abezel, a dual function air-gap switch actuator configured as a lever,and a vertical column of light emitting diodes. The dual functionair-gap switch is mechanically co-operable with the pair of air-gapcontacts and operates to open and close these contacts. The bezel kit isconfigured to allow various sized buttons operable by the user toinitiate a primary function to be snapped into the bezel prior toattachment with the dimmer enclosure. The air-gap contacts are adaptedto open when the bezel kit is separated from the dimmer enclosure. Thedual function air-gap switch actuator is further adapted to be operableby the user to provide a synchronization function with a centralizedlighting controller.

The present invention seeks to overcome or at least ameliorate one ormore of several problems, including providing secondary functions withadding additional switches to the face of a wall mounted dimmer.

DISCLOSURE OF INVENTION

To solve the aforementioned problem, a physical air-gap switch mechanismis provided, to be activated in special circumstances when an air-gap isneeded. As activating the air-gap switch is not a typical behavior, itis advantageous to give this switch a secondary function since it isalready occupying available space of the face of the dimmer.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying figures further illustrate the present invention.

The components in the drawings are not necessarily drawn to scale,emphasis instead being placed upon clearly illustrating the principlesof the present invention. In the drawings, like reference numeralsdesignate corresponding parts throughout the several views.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 is a perspective view of a wall box dimmer (with a decorativefaceplate shown) and showing the novel dual function air-gap switchactuator in the closed “power on” position.

FIG. 2 is a wireless lighting system having a centralized lightingcontroller and incorporating the inventive wall dimmer of the presentinvention.

FIG. 3 a front view of the wall box dimmer shown in FIG. 1.

FIG. 4 further illustrates wall box dimmer of FIG. 1 showing the noveldual function air-gap switch actuator in the open “power off” position.

FIG. 5 further illustrates the dual function nature of the inventiveswitch actuator by depicting a second illustrative embodiment of thepresent invention.

FIG. 6 schematically depicts certain electrical elements of the wall boxdimmer shown in FIG. 1 according to one illustrative embodiment of thepresent invention.

FIG. 7 depicts timing diagrams for several example commands operable forcertain embodiments of the present invention.

FIG. 8 depicts an embodiment of the inventive wall box dimmer having asingle primary function button.

FIG. 9 depicts an embodiment of the inventive wall box dimmer having atwo primary function buttons.

FIG. 10 depicts an embodiment of the inventive wall box dimmer having afour primary function buttons.

LIST OF REFERENCE NUMBERS FOR THE MAJOR ELEMENTS IN THE DRAWINGS

The following is a list of the major elements in the drawings innumerical order.

-   -   20 wall box dimmer(s)    -   21 enclosure (part of dimmer 20)    -   22 removable bezel kit (part of dimmer 20)    -   23 bezel (part of bezel kit 22)    -   24 primary function button (part of bezel kit 22)    -   25 vertical column of light emitting diodes (LED)    -   26 dual function air-gap switch actuator    -   31 faceplate    -   32 electrical wall box    -   41 centralized lighting controller    -   42 lighting load(s)    -   51 example first command—single increment increase (decrease)        brightness    -   52 example second command—full brightness (dim)    -   53 example third command—step through increasing (decreasing)        brightness increments    -   example fourth command—manually set continuous increasing        (decreasing) brightness    -   211 air-gap contacts (main power disconnect)    -   212 secondary function switch (mounted within enclosure 21)    -   215 dimmer “up” switch (activated by primary function button 24)    -   216 dimmer “down” switch (activated by primary function button        24)    -   241 primary function button (single=1)    -   242 primary function button(s) (dual=2)    -   244 primary function button(s) (quad=4)    -   254 alternate LEDs (corresponding to buttons 244)    -   261 first end portion (of dual function air-gap switch actuator        26)    -   262 second end portion (of dual function air-gap switch actuator        26)    -   265 indicator lamp (integral to switch actuator 26)

DETAILED DESCRIPTION OF THE INVENTION

The present invention is generally implemented as part of a wall boxdimmer. Hence, an illustrative dimmer system and its operation will bedescribed initially.

Unless the context clearly requires otherwise, throughout thedescription and the claims, the words ‘comprise’, ‘comprising’, and thelike are to be construed in an inclusive sense as opposed to anexclusive or exhaustive sense; that is to say, in the sense of“including, but not limited to”.

MODE(S) FOR CARRYING OUT THE INVENTION

The preferred embodiment of the present invention is described herein inthe context of a wall box mounted dimmer, such as one that might befound in a residence, but is not limited thereto, except as may be setforth expressly in the appended claims.

Referring first to FIG. 1, there is shown a wall box dimmer 20, whichhas a generally planar bezel of any suitable material such as moldedplastic and an enclosure 21 which includes various electronicscomponents. According to the present invention, the bezel is actually asubcomponent of a removable bezel kit 22, which also other componentswhich will be described below.

The wall box dimmer 20 is typically installed in an electrical wall box32 as is well known to those skilled in the art of residential andcommercial construction. The dimmer bezel extends through an opening ina faceplate 31. Those skilled in the art will recognize that faceplate31 may be further comprised of a mounting plate portion and asnap-connect decorative faceplate portion. All of these parts can bemanufactured from molded plastic.

FIG. 2 depicts a lighting system, such as might be used in either asmall commercial or large residential installation, and which includesthe inventive dimmer of the present installation. A centralized lightingcontroller 41 communicates with several wall box dimmers, such as thepresent inventive dimmer 20. Each of the dimmers 20 is associated withand controls a corresponding lighting load 42 and also provides an airgap switch to physically connect and disconnect the dimmer 20 with itscorresponding lighting load 42. In certain embodiments, the centralizedcontroller 41 is hard-wired to each of the dimmers 20 and in otherembodiments; the dimmers intercommunicate with one another and thecentralized controller 41 using a wireless mesh network wireless meshnetwork.

Advantageously, the additional secondary function added to the air-gapswitch can be used to synchronize communications between the variouslighting system components shown in FIG. 2.

FIG. 3 illustrates further detail of the components that comprise bezelkit 22, according to one embodiment of the present invention, as seenthrough the faceplate 31 such as in a typical residential installation.A primary dimming function for wall box dimmer 20 is activated by anoperator using primary function button 24, such as for example a rockeractuator. Operator feedback, such as button status, dimming level,wireless network signal, or lighting system environmental ‘green’ levelis indicated by a vertical indicator, such as a vertical column of lightemitting diodes 25. The dual function air-gap switch actuator 26 allowsfor physical disconnect of the lighting load as described previously. Inone embodiment of the present invention, the operator can depress afirst end portion 261 of dual function air-gap switch actuator 26 toactivate a secondary function, such as setting a default dimmingschedule.

Refer now to FIG. 4 which shows a dual function air-gap switch actuator26 in the open, power “OFF” position in accordance with one illustrativeembodiment of the present invention. In this embodiment, the air-gapcontacts internal to dimmer enclosure 21 are configured as amicro-switch which is opened and closed by rotary motion of air-gapswitch actuator 26. Advantageously, in this embodiment, separating thebezel kit 22 from the enclosure 21 causes the air-gap contacts to openthereby protecting the user from exposure to potentially live electricalcomponents.

In a preferred embodiment, the dual function air-gap switch actuator 26is implemented as a small horizontal lever has been designed which, whenrotated in one direction, opens a micro switch which physicallydisconnects the lighting load from the alternating current (AC) line.This lever sits directly below the device's buttons, and blends inaesthetically.

FIG. 5 further illustrates the dual function nature of the inventiveswitch actuator by depicting a second illustrative embodiment of thepresent invention. In this embodiment, the air-gap contacts 211 areconductively connected through the air-gap switch actuator 26 and areopened and closed by an operator grasping and pulling on the first endportion 261 of the dual function air-gap switch actuator 26 in a rotaryfashion. A depression of a second end portion 262, of the dual functionair-gap switch actuator 26, in a linear fashion activates a secondaryfunction switch 212, mounted within enclosure 21. In other embodiments,the secondary function is activated by depressing the first end portion261 of the dual function air-gap switch actuator 26 in a linear fashion.Significantly, the full front appearance of the entire assembly (withthe dual function air-gap switch actuator 26 in the closed “power on”position and the internal dual function air-gap switch closed) is thatof a substantially flat uncluttered surface. (See for example, thesubstantial planarity of the front surface in FIG. 1).

Other embodiments incorporate different configurations of air-gapcontacts and different switch configurations for activating thesecondary function. Advantageously, the secondary function is providedwithout requiring additional awkwardly placed switches or the like. Thissecondary function can include a number of functions, including but notlimited to: (a) an internal software reset, (b) providing a “save”functionality when tapped to allow the end user to adjust storedlighting preset levels, or; (c) providing a synchronization functionwith a centralized lighting controller.

FIG. 6 depicts certain electrical elements of the inventive wall boxdimmer 20 for one embodiment which incorporates a rocker actuatorprimary function button 24. This primary function button 24 can bealternately operated to depress either a dimmer “up” switch 215 or adimmer “down” switch 216. The dual function air-gap switch actuator 26can be alternately operated to either depress a secondary functionswitch 212 or to open and close air-gap contacts 211. Also shown is avertical column of light emitting diodes (LED) 25. In a furtherembodiment of the present invention, an indicator lamp 265, such as ahigh efficiency LED lamp is incorporated into the dual function switchactuator 26.

Refer now to FIG. 7 and continue to refer to FIG. 6. A timing diagramassociated with one illustrative embodiment of the present invention isprovided to describe several example commands executed by dimmer 20. Thereference characters “S1”, “S2”, “S3”, “S4”, and“S5” indicate a set ofinternal states that can be used to determine the particular desiredcommand in accordance with an illustrative embodiment of the presentinvention.

Four example commands, operable from the dimmer “up” switch 215, areshown. The example first command 51 consists of a short single tap (i.e.“single-click”) on the dimmer “up” switch 215 and acts to increase thebrightness of a controlled lighting load to the next programmedincrement. An example second command 52 consisting of a short double tap(i.e. “double-click”) acts to increase the controlled lights to theirmaximum brightness. An example third command 53 consisting of acontinuous depression of the dimmer “up” switch 215 causes thebrightness to step through a sequence of programmed brightness levels,such as at a rate of ten (10) brightness levels per second.

Finally, an example fourth command 54 consisting of a single short tapimmediately followed by continuous depression causes the brightness tocontinuously increase through all brightness levels at a predeterminedrate. In this embodiment, a short depression of the dual functionair-gap switch actuator 26 (i.e. “single-click”) activates the secondaryfunction which in turn causes the manually set brightness level to beadded to the programmed sequence of brightness levels. In thisembodiment, the dimmer “down” switch 216 switch operates in an analogousmanner.

FIGS. 8, 9, and 10 illustrate several embodiments of the inventivedimmer in which various configurations of buttons have been incorporatedinto the bezel kit 23. Advantageously, the particular buttonconfiguration can be altered without removing the wall box dimmer 20from the electrical wall box 31, shown in FIG. 1. Changing buttonconfigurations is accomplished by simply removing the bezel kit andchanging out the buttons.

The button functions, with the exception of the air-gap switch contacts,are all software configurable. For example, in certain embodiments,multiple secondary functions are provided by the dual function switchactuator 26: (a) a single short tap stores the present lighting level asa preset; and (b) a continuous resets the programmed brightness levelsto factory set defaults or downloads the default levels from a centrallighting controller.

Refer now to FIG. 8. The wall box dimmer consists of enclosure 21 andattached bezel kit 22. Bezel kit 22 consists of a bezel 23 that includesa vertical column of LEDs 25 and the inventive dual function switchactuator 26. In this embodiment, one primary function button 241 isinstalled within bezel 23 and the vertical column of LEDs 25 isconfigured as a bar graph indicator which indicates the commandedlighting level.

In the embodiment shown in FIG. 9, two primary function buttons 242; areinstalled within bezel 23 and the vertical column of LEDs 25 isconfigured as a bar graph indicator which indicates the commandedlighting level. As described previously, bezel kit 22 includes the bezel23 and the inventive dual function switch actuator 26.

In the embodiment shown in FIG. 10, four primary function buttons 244;are installed within bezel 23 and the bezel kit 22 further includes thebezel 23, the inventive dual function switch actuator 26, and thevertical column of LEDs 25. In this embodiment, the vertical column ofLEDs includes seven LEDs, spaced to line up with the primary functionbuttons. More specifically, alternate LEDs 254 are aligned withcorresponding primary function buttons and the remaining LEDs that arenot aligned with corresponding buttons are powered off.

Although the present invention has been described in relation toparticular embodiments thereof, many other variations and modificationsand other uses will become apparent to those skilled in the art. It ispreferred, therefore, that the present invention be limited not by thespecific disclosure herein, but only by the appended claims.

INDUSTRIAL APPLICABILITY

To solve the aforementioned problems, the present invention is a uniquedual function air-gap switch configuration that incorporates additionalfunctionality while still maintaining the required air-gap switchfunctionality in the same physical space constraint.

LIST OF ACRONYMS IN THE DETAILED DESCRIPTION

The following is a list of the acronyms used in the specification inalphabetical order.

AC alternating current

FET field effect transistor

LED light emitting diode

SCR silicon controlled rectifier

Alternate Embodiments

Alternate embodiments may be devised without departing from the spiritor the scope of the invention. For example, additional indicator lampscould be incorporated into the dual function air-gap switch actuator..

1. A wall box dimmer having a generally planar face and adapted to mountbehind a faceplate (31), said dimmer comprising: (a) an enclosure (21)containing a pair of cooperating air-gap contacts (211) interiorlythereof; (b) a removable bezel kit (22) protruding through an opening insaid faceplate and further comprising (i) a bezel, (ii) at least oneprimary function button (24) operable by a user to initiate a primaryfunction, (iii) a dual function air-gap switch actuator (26)mechanically cooperable with said pair of air-gap contacts and adaptedto open and close said pair of air-gap contacts; and (c) wherein thedual function air-gap switch actuator is further adapted to be operableby the user to initiate an internal software reset and the bezel kit isconfigured to allow various sized buttons to be snapped into the bezelprior to attachment with the dimmer enclosure.
 2. A wall box dimmerhaving a generally planar face and adapted to mount behind a faceplate,said dimmer comprising: (a) an enclosure containing a pair ofcooperating air-gap contacts interiorly thereof; (b) a removable bezelkit protruding through an opening in said faceplate and furthercomprising (i) a bezel, (ii) at least one primary function buttonoperable by a user to initiate a primary function, (iii) a dual functionair-gap switch actuator mechanically co-operable with said pair ofair-gap contacts and adapted to open and close said pair of air-gapcontacts; and (c) wherein the dual function air-gap switch actuator isfurther adapted to be operable by the user to adjust stored lightingpreset levels and the bezel kit is configured to allow various sizedbuttons to be snapped into the bezel prior to attachment with the dimmerenclosure.
 3. The wall box dimmer of claim 2 wherein the dual functionair-gap switch actuator provides a save functionality when tapped toallow the end user to adjust stored lighting preset levels.
 4. The wallbox dimmer of claim 3 wherein the at least one primary function buttonis configured to raise light levels to a desired level and the dualfunction air gap switch is configured to adjust stored lighting presetlevel to the desired level.
 5. A wall box dimmer having a generallyplanar face and adapted to mount behind a faceplate (31), said dimmercomprising: (a) an enclosure (21) containing a pair of cooperatingair-gap contacts (211) interiorly thereof; (b) a removable bezel kit(22) protruding through an opening in said faceplate and furthercomprising (i) a bezel, (ii) at least one primary function button (24)operable by a user to initiate a primary function, (iii) a dual functionair-gap switch actuator (26) mechanically cooperable with said pair ofair-gap contacts and adapted to open and close said pair of air-gapcontacts; and (c) wherein the dual function air-gap switch actuator isfurther adapted to be operable by the user to provide a synchronizationfunction with a centralized lighting controller and the bezel kit isconfigured to allow various sized buttons to be snapped into the bezelprior to attachment with the dimmer enclosure.